Sintech Precision Products

P Liimited
C-189/190 0, Bulandsha
ahar Road Inndustrial Areaa,
Site No. 1,, Ghaziabad
d – 201001 (U
U.P.), INDIA.
Ph.: +91-120-4176000,, 3290637/388, 2866320/21 1
ww
[Link]
[Link] Fax: +91-1120-2867715
Email: sales@sintech
[Link]

INSSTALLLATTION
N
OPPERA ON AND
ATIO
MAAINTTENA ANCCE
MAANUUAL FOR
F
SM
MF PU UMP PS

CONTROL COPY
Y NO. S
SPPL/OM/
/SMF/11

REV. NO
O. R
R2

REV. DA
ATE 28/07/2014
4

P
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WARRANTY:
1. Seller warrants products of its own manufacture and workmanship under normal use and service
for one (1) year from date of installation or start‐up, but not more than eighteen (18) months
after date of shipment.
2. Accessories and components not manufactured by seller are warranted only to the extent of the
original manufacturer’s warranty.
3. No allowances will be made for repair or alteration effected without specific written
authorization from seller.
4. Repairs or alteration made with other than genuine SINTECH original equipment parts may VOID
the warranty and relieve the seller of all product responsibility.
5. This warranty is VOID unless the purchaser provides protective storage, installs and maintains
the equipment in accordance with manufacturer’s instruction.
6. Under terms of this warranty, seller shall not be responsible nor liable for:
a. Consequential, collateral or special losses or damages.
b. Equipment condition caused by fair wear and tear, abnormal condition of use, accident,
neglect, or misuse of said equipment.
c. Labour charges, loss or damage resulting from supplying of defective part(s) or improper
repairs by unauthorized person(s).
d. Damage caused by abrasive materials, chemicals, scale deposits, corrosion, lightening,
improper voltage or mishandling.

NOTE:‐
AS PER THE COMPANY’S POLICY OF CONTINUOUS IMPROVEMENT, THE
SPECIFICATIONS & DATA GIVEN IN THIS MANUAL ARE SUBJECT TO CHANGE
FROM TIME TO TIME WITHOUT NOTICE.

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CONTENTS:‐
1. Introduction ………………………………………………………………………....…4
2. Salient features ………………………………………………………………………..4
3. Special Features ……………………………………………………………………….4
4. Constructional features ………………………………..……………………….…4
5. Material of construction ………………………..…………….…..……...….…5
6. Application ………………………………………………………………………..……5
7. Receiving and handling pump ……………..…………………………..……..8
8. Temporary Storage …………………………………….………….....…..........8
9. Installation …………………………………………………………………………....11
10. Operation …………………………………………………………..………………….28
11. Maintenance ……………………..…………………….……………………..…….29
12. Stuffing box ……………………………..………………………………..…...…….33
13. Stuffing box with mechanical seal ………………………………………….38
14. Overhauling …………..……….……………………….……………………….……41
15. Trouble Shooting …………….…………………………………………….……….62
16. Spare parts ………………………………….……………………………………..….64
17. General information and safety requirements …..……………......65
18. ORDER FORM FOR PUMP SPARE PARTS …………….………………….68

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 General instructions for installation operation and maintenance of Horizontal
SMF pump
1. INTRODUCTION
The Horizontal SMF pumps are designed for specific capacity, speed, pressure and temperature.
These pumps are manufactured to close tolerances and rigid specification each and every pump is tested
at works for performance and trouble fee operation before dispatch.
If pump is operated beyond the conditions for which it is designed, the pump will be subject to
excessive stress and Strains.
The pumps covered by these instructions, when properly installed and proper care taken during
operation maintenance and repair, will give long satisfactory service.
Our Guarantee will be valid only if the installation, Operation, maintenance and repair of the pumps
are carried out in accordance with our instructions and refer Fig-1&2 before installation

Note: -
Do not remove the cover plate protecting suction and delivery opening Before
installation of pipes to protect against foreign particles/pest inside the pump Which may
damage it at starting.

2. SALIENT FEATURES
The SMF series are single‐stage centrifugal pumps suitable for handling pure or contaminated liquids
in large quantities. These pumps are of robust construction and have long working life. These pumps are
also low in energy consumption due to very good efficiency.
The precision machined pump shaft is seated in amply oil/grease lubricated and protected by a shaft
sleeve in the stuffing box area. The integrally cast feet of the casing transmit any forces originating from
the pipe work directly to the foundation, this means that the rotor is not subjected to any bending stresses
and thus optimal working life of the bearings is assured.
Electric motors can be used as the prime mover. With diesel engine as the prime‐mover, the pump’s
direction of rotation is anticlockwise from the driven and.
3. SPECIAL FEATURES
SMF Pumps are normally recommended for clear cold water having turbidity maximum 50 ppm
(Silica Scale), chloride maximum 550 ppm. Total solids 3000 ppm. PH value between 6.5 and 8.5 and
specific gravity around 1.0 SMF pumps can be offered for liquids having viscosity upto 1000 SSU.
4. CONSTRUCTIONAL FEATURES
These are three / four vane impeller pumps (in standard pump) specially designed to pass solid or
stingy material. Hand hole are provided in the casing and near the throat of impeller. Pumps are available
in horizontal & side discharge construction, vertical dry pit or wet pit construction with motor directly
mounted on the pump or at an elevation and connected through intermediate shaft.
Casing: ­ Pump casing is high strength cast iron with ample section thickness to product a large factor
of safety over the maximum allowable working pressure. The casing is enclosed by a suction and
stuffing box cover or head carefully machined to assure perfect alignment. Suction and discharge
nozzles and the supporting feet are cast integral with the casing. All Flange are drilled according to BS
10 table D. Drilled as per DIN/ASA is also possible on specific request.

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 Impeller: ‐ The Impeller of SMF pumps are made of SS 304 (in standard pump). The impeller is semi‐
open type having passages into which passages into which the liquid flows direct and unimpeded. The
impellers are provided with balancing holes for balancing the axial thrust. They are also dynamically
balanced to counter the vibrations. Impellers in other materials such as close grained cast iron, bronze,
phosphors bronze Ni‐cast iron, cast steel etc. are also available on request.
Bearing Housing Assembly:‐The rotating assembly is supported on heavy duty bearings mounted in
a precision bored frame. Bearing are carefully sealed to exclude moisture and contaminants and retain
lubricant.
Stuffing Box: ‐ Extra deep design and features a gland to simplify replacement of gland packing.
Packed stuffing box with lantern rings is the standard arrangement. It is sealed internally. However,
against special requirement, sealing by external fluid is also provided.
Shaft: ‐ Machined from high quality steel, the shaft is sturdy design to minimize deflection and provide
long reliable service. Shaft is protected by sleeve from in stuffing box area.
Direction of Rotation: ‐ Clockwise viewed from the drive end.

5. Material of Construction
Parts Name All Cast 02s CF 8 CF 8M Bronze
Iron Fitted Fitted Fitted Fitted
Volute Casing Cast Iron Cast Iron CF 8 CF 8M Bronze
Impeller Cast Iron CF 8 CF 8 CF 8M Bronze
Stuffing Box Cast Iron Cast Iron CF 8 CF 8M Bronze
Shaft EN 8 SS 410 SS 410 SS 316 SS 316
Sleeve SS 410 SS 410 SS 410 SS 316 SS 316
Bearing Cast Iron Cast Iron Cast Iron Cast Iron Cast Iron
Housing

Other than above state materials pumps are available in Cast Steel, CA 15, NI-Resist, Super Duplex,
CN7M, Haste alloy and other special stainless steel alloys.
The materials of construction are offered as examples of generally accepted practice, but are not
intended as recommendations of fitness for a particular purpose. The customer must determine and take
the ultimate responsibility for specifying the proper materials to handle the particular fluid pumped. Unless
otherwise specified, all pumps shall be furnished with the standard fitted materials.
6. APPLICATION
SINTECH SMF horizontal pumps are used in these application
 General Water Supply
 Water treatment
 Injection and Spray
 Condensate
 Water supply
 Cooling tower
 Power industry utilities
 Storm water and drainage
 Sewage Disposal

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7. RECEIVING AND HANDLING PUMP
The pump is dispatched from factory in assembled condition and in crate or in a wooden box
specially designed for transport by truck.
Upon receipt check the pump usually to determine whether any damage has happened during
transpiration or handling.
Check especially for these points.
A. Broken or cracked equipment including base frame, motor or pump flange and feet.
B. Broken motor fan cover, bent eye bolts bent shaft or damaged terminal box.
C. Missing Parts.
D. Pump shaft rotates freely
If any damage or losses have occurred, promptly notify SINTECH representative and the transporters
agent, who deliver the pump.
When unloading pump units. Lift equally at four points from the base. Do not lift only the driver or
pump (Fig 3&4).
Care must be exercised in handling particularly the shaft and if bent can cause trouble.

8. Temporary storage.
If pump is not to be installed and operated soon after arrival, store it in a clean dry place with slow
changes in ambient temperature. Protect the pump from moisture, dust, dirt and foreign bodies. During
storage following precautions to be taken

1. Ensure that the bearings are packed with recommended grease to prevent moisture from entering
around shaft.
2. Ensure that suction and discharge opening of the pumps and other openings are covered with
cardboard or other material to prevent foreign objects entering the pump.
3. If pump is to be stored in open or where there is no other suitable covering, cover the unit with
tarpaulin or other suitable covering.
4. Rotate the shaft usually every week to prevent corrosion of the bearing surfaces and the stuffing
box/shaft seal faces due to moisture.
5. If pump is to be stored for long time then before installing change the grease and gland packing

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9. INSTALLATION
All installations should be performed by experienced personnel in placement, alignment and
connection of pumping equipment. Before installing the pump clean the suction and discharge flanges.
Remove the protecting coating from the pump shaft.
If the pump has been in storage remove grease from the bearings and the bearing shaft then be
flushed with carbon tetrachloride or kerosene and re‐lubricated.

9.1 LOCATION
1. Selection the location for pumping unit, which will be clean, well ventilated, properly drained and
provides accessibility for installation and maintenance, allow space and head room for the use of
overhead crain or hoist sufficiently strong to lift the unit.
2. If some connections of water or liquid are required for flushing cooling, lubrication etc. ensure that
they are available for maintenance and inspection.
3. The suction system must provided the pump with net positive suction head (NPSH )equal to or
grated than that required by pump.
4. The pump should be location as near to fluid supply as possible so that a short direct suction pipe
can be used so that suction losses are minimum. The discharge pipe should be direct and with as
minimum elbow and fitting as possible.

9.2 FOUNDATION
A. Prepare the foundation keeping in view the type of sail at site.
B. The pump with base frame should be installed on consented foundation which is strong enough to
provide permanent and rigid support for the entire pump.
The foundation must be capable of absorbing any vibration, normal strain or shock. As a rule of
thumb the weight of the concrete foundation should be 3‐5 time the weight of complete pump unit.

9.2.1 Pouring the foundation

Pour the foundation without interruptions to within 20‐40 mm of the final level. Ensure that the
concrete is evenly distributed. The top surface of the foundation should be well scored and grooved
before the concrete. This set will provide a bonding surface for the grout. Embed foundation bolt in the
concrete as shown in (Fig‐ 5) allow enough bolt length to reach through grout, shims, lower base frame,
nuts and washer. The foundation properly should be allowed to use properly base frame is grouted.
9.3. MOUNTING AND LEVLLING
A. Lift the base frame on which the pump unit is coupling with the motor should be placed on
foundation.
B. Disconnects coupling halves.
C. Base frame should be supported on metal block or shims or metal wedges having small taper. The
support pieces should be placed closed to foundation bolts and midway between bolts (Fig‐6).
D. Level the base frame by adjusting shims under the base frame. A gap of about 20 mm – 40 should be
allowed between base frame and foundation for grouting. Check the coupling faces, Suction and
discharge flanges for horizontal and vertical positive by means of level.
E. Tighten the foundation bolts nuts against the base frame. Make sure that the piping flanges without
putting strain on pipes or flanges.
F. Machine surface of base frame can be used as reference for leveling purpose. The leveling should be
done with help of precision engineer’s sprit level.
G. Please note that the base Plate are flexible to some extent and therefore must not be relied upon to
maintain the factory alignment. Realignment may be necessary after the complete unit has been
leveled on the foundation and again after the grout has set and foundation bolts are tightened.

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9.4 ALIGNMENT OF COUPLING
The flexible coupling pump & motor is properly alignment with in proper limit on its base plate at the
factory. This alignment may be disturbed due to following factors.

a) Setting of foundation.
b) Deformation of base plate. During transits and/or handling.
c) Springing of base frame.
d) Piping strain.
e) Shift of pump or driver on foundation.
f) Wears of the bearing.

Grout setting and other reasons. It is therefore essential to check alignment prior to final grouting.
A flexible coupling will not compensate for misalignment of the pump and driver its purpose is to
allow for temperature changes and to permit independent. Movement of the pump and motor shafts.
When the pump and motor shafts are pulled, there should be 3 mm minimum gap between the
coupling faces. There coupling should not be used to compensate for excessive misalignment of pump
and motor shaft ,inaccurate alignment result in vibration and excessive wear of the bearings , shafts and
wear rings .

9.4.1 PROCEDURE FOR COUPLING ALIGNMENT

A. Disconnects coupling halves
NOTE: ‐ before starting work on the pump, make sure that the power supply has been switched off and that
it can not be accidently switched on.
B. Set the required gap between coupling faces depending upon the coupling size.

For a coupling with an outside diameter of @ MM The coupling gap between faces.
Normal Tolerance
@ 90‐215 3.2 01‐1
@ 251‐270 4.8 01‐1
@ 360‐@750 8.4 01‐1
Note that keyways are 180⁰ displaced.
Carry out alignment of the motor by placing shims of different thickness under the motor, if
possible replace several thin shims with one thick shim
There are two forms of misalignment
A. Angular: shaft with axes concentric but not parallel.
B. Parallel: shaft with axes parallel but not concentric.
a. To check for angular alignment insert a pair of inside caliper or a taper gauge at four points at
90.C interval around the coupling (See Fig 7) angular alignment show that all points of the
coupling are within +‐ 0.2 mm of each other
b. To check parallel alignment place a straight edge across both coupling rims at the top, bottom
and both sided (SEE Fig 8) after each adjustment recheck all features all alignment ,parallel
alignment is correct when the measurement show that all point the coupling faces are within +‐
0.2 mm of each other

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9.5 GROUTING
Unless other vise specified, the base frame must be completely filled with grout and the leveling
wedges grouted in place. The product warranty may be void if these instructions are not followed.
When the alignment is correct the foundation bolts should be tightened evenly. The unit should
then be grouted to the foundation. The foundation bolt should not be tightened until grout is hardened,
usually 48 hrs after pouring.
Grouting compensates for uneven foundation, distributes weight of unit, minimizes vibrating and
prevents shifting of unit. Use an approved non shrinking grout and pumping unit should be grouted by
experts.
The mix required varies with the type of unit to be grouted, location and amount of grout, grout
unit as follows.
A. Build a form of thick plan around the foundation to contain the grout.
B. Sock top of concrete foundation thoroughly then surface water.
C. Fill the form with grout up to the top edge of the base frame see (Fig 9). While pouring tamp
liberally in order to fill all the cavities and preventing air pockets.
D. After the grout has thoroughly has dined tighten the foundation bolts and connect the piping.
Ensure that the piping does not exert any strain on the pump flanges.
E. Check the alignment after piping is connected and foundation bolts are tightened. If realignment is
required, disconnect the piping first then proceed with alignment. reconnect the piping after
alignment has been completed and recheck the alignment before connecting the coupling (Fig 10)
9.6 PIPING
9.6.1 Protective cover is fitted to the suction and discharge flanges to prevent foreign bodies from
entering, the pump during transportation and installation. Make sure these covers are removed
from the pump before connecting any pipes.
9.6.2 SUCTION AND DISCHARGE PIPE
In order to minimize losses and hydraulic noise in the piping , choose pipe size one or two size
higher than the pump suction and discharge size typically flow valuated suction not excess 2m/sec for
the suction pipe and 3m/sec for the discharge pipe.
Make sure that the available is higher the NPSH required.
9.6.3 GENERAL PRECAUTIONS
When installing the piping observe these precautions.
A. Always run the piping direct to the pump.
B. Do not move pump to piping this could make final alignment difficult and cause stress to pump
flanges and piping.
NOTE: MAKE SURE THAT BOTH SUCTION AND DISCHARGE PIPING ARE INDEPENDENTLY
SUPPORTED NEAR THE PUMP SO THAT NO STRAIN IS TRANSMETTED TO THE PUMP WHEN THE
FLANGE BOLTS ARE TIGHTENED
C. Install piping as straight as possible and avoid unnecessary bends. Where necessary use 45⁰ or
long sweep 90⁰fittings to reduce friction loss.
D. Make sure all joint are air tight.
E. Where flanged joints are used ensure that inside diameters match properly.
F. Remove burr and sharp edges when making joints.
G. Make sure that the piping does not cause stress or strain in the pump.
H. Always allow sufficient space for maintenance and inspection.
9.6.4 SUCTION PIPING
Locate the pump below system level whenever possible. This will facilities priming, assure a steady
liquid flow and provide a positive suction head.

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 NOTE: the sizing and installation of the suction piping is externally important. Many NPSH problems
can be avoided with proper installation of suction pipe.
The common suction piping installation is shown In (FIG 11A, 11B, 11C& 11D).

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9.6.5 DISCHARGE PIPING
The discharge pipe should be as direct as possible with a minimum of valve and elbow to
minimize pipe friction loss.
A check valve and a sluice valve should be installed with check valve between the pump and
gate valve/ swish valve. The non return valve / check valve protect the pump against excessive
pressure and reverse rotation of pump and back flow in case of failure of motor. (Fig‐12)
In order to minimize frictions losses and hydraulic noise in the pipe work, flow velocity should
not exceed 3m/sec in the discharge pipe on long horizontal runs it is desirable to keep the piping as
level as possible. Avoid high spots, such as loops as they will collect air and throttle the system or
lead to uneven pumping.
NOTE: the pump must never be throttled by the use of valve in suction line.
The discharge valve is used in priming, starting and when shutting down the pump.
9.6.6. Auxiliary piping connection and gauges
In addition to primary piping connection, pump may require connection to the water
seal ring and mechanical seal stuffing box drain, discharge and pressure gauge connection
all these connected now be installed. (Fig 12A, 12B & Table given below)

SMF PUMP ‐ TAPPING CONNECTION CHART

Code Description Location of Connection
A Gauge Connection‐Discharge side. On Pump discharge flange side.
B Gauge suction side On suction flange side.
C Circulation line connection from casing. On Pump discharge driving side.
D Pump casing drain. On Pumps casing bottom side to wards suction.
E1 Stuffing box, M. Seal cooling water inlet. On casing cover top right.
E2 Stuffing box, M. Seal cooling water Outlet. On casing cover bottom left.
H Oil feeding plug. On bearing housing top.
K Oil level indicator. On bearing housing left.
M Bearing housing oil drain. On bearing housing left.
N Drip pan drain. On lantern Bracket bottom right.
G Vent On top of Casing

a. Install drain pipe from pump casing and stuffing box to a convenient disposal point.
b. Flushing pipes
1. Pumps fitted with stuffing box
When suction pressure is below ambient pressure, supply to the stuffing boxes with liquid to
provide lubrication and prevent the ingress of air. This is normally achieved via flushing pipe from
the pump discharge side to the stuffing; a control valve may be fitted in the flushing pipe to control
the pressure to the stuffing box.
If the pumped water is dirty and cannot be used for flushing the packing. A separated clean
compatible liquid supply to stuffing box at 1 Kg/cm2 above the suction pressure is recommended.
2. Pumps fitted with mechanical seal
Seal requiring recirculation will normally be provided with a flushing pipe from pump casing.
To avoid seal damage, we recommend that the supply of any external flushing or cooling
liquid is continued after the pump is stopped.

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10. Operation
10.1 Start up checks.
Before starting and after service repair always check the following
A. The unit base plate is grouted and bolted to foundation.
B. All auxiliary pipe connection and fittings have been completed.
C. Before starting the pump, rotate the unit or assembly by hand to ensure rotation of moving part.
D. The motor direction of rotation has been checked and correct.
E. Before starting the pump, all the guards have been installed around all exposed rotation parts.
F. The coupling has been properly aligned between pump and motor.
G. Never run the pump dry as the close running fits within the pump are water lubricated, Running dry may
result in pump seizure.
H. Lubricated bearing with grease if not done.
I. Before starting the pump, fill the casing and suction line with liquid. The pump may be primed with ejector
or vacuum pump.
J. Before starting a mechanical seal pump, turn on the seal water, vent. The seal housing and confirm seal
water is at sufficient pressure.
K. Before starting a stuffing box pump, adjust the packing gland so that there is sufficient leakage to lubricate
the packing and ensure cooling of stuffing box.

10.2 Starting
i. Check that suction valve is fully open and discharge and drain valve fully closed.
ii. Start the pump; let the prime mover pick up full speed.
iii. Open the valve on delivery line slowly.
iv. Regulate the required flow by adjusting the delivery valve.
v. Open the cock for pressure gauge connection.
vi. Turn on seal water to the stuffing box where external water is supplied.

10.3 During running the pump, check the following things and regulate if necessary.
A. The pump is running smooth.
B. the flow of sealing liquid and cooling/heating water is uninterrupted
C. The bearings are not getting heated up abnormally.
D. The glands are properly tightened to ensure sufficient leakage to dissipate the heat and control the
temperature of gland .The maximum permissible leakage is 60‐80 drops per minutes.
E. Check Head and capacity developed by pump
F. Check Power Consumption is within limit.
G. Ensure that there is no mechanical friction in the pump.
H. Check the temperature and vibrations of bearing regularly. If one or the other increases, it may be
a sign of improper lubrication or bearing damage.
I. Unusual noise from pump should also be investigated and their cause be rectified.

10.4 Stopping the unit

1. Close the discharge valve to prevent the pumped liquid from flowing back.
2. Stop the driver/motor.
3. Close the suction valve.
4. Close the cooling and flushing valve.
5. Successful operation of pump depends on accurate alignment. It is recommended to re check the
alignment after prelim in run.

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 10.5 Bearing operating temperature
The pumps are designed to operate a wide ambient temperature range. The bearing
temperature, when measured on the outside surface of the bearing housing should normally be
around 130⁰F (54⁰c) with ambient of 70⁰F (22⁰C). High speed operation may have higher bearing
temperature but these temperature should not exceed 190⁰F (87⁰C). Temperature in excess of 190° F
may indicate a lack of lubricant, or bearing problems.
It the temperature exceeds 190º F, the pump should be stopped and cause to be investigated
and corrective action to be taken accordingly
In case of new bearing renew the oil after about 200 hours and then about once a year. If
bearing temp is always below 50⁰C and there is only small risk of contamination. If the bearing
temperature is up to 80⁰C and if there is damages of contamination the oil should be renewed every
six months.
1. Bearing of reputed make equivalent are used.
2. C3 clearance bearing are used.
3. Axial running clearance shall be less than 0.45 mm for all about bearing arrangement.
4. Maximum allowable temp of bearing shall be 80⁰C
5. Bearing are oil lubricated oil level in bearing housing is maintained up to the required level
with help of constant level oil indicator.
6. In case of pumping liquids above 150⁰C cooling lubricating oil shall be necessary, however
bearing housing cooling arrangement shall be provided at an extra cost and against specific
request only.
11. Maintenance
11.1 Inspection and preventive maintenance requirement
For satisfactory operation pump, daily inspection and periodic maintenances are required.
11.2 Daily Checks
2.1 An hourly record of suction and delivery pressure, discharge, input power to pump drive
should be maintained.
2.2 bearing temperature, oil level, stuffing box leakage/ stuffing box temperature, cooling
water inlet and outlet temperature should be checked and recorded. This gives an idea of
mechanical performance of the pump.
2.3 Noise and vibration is the first sign the starting trouble like cavitations, air lock, bearing
failure, chocking of Impeller of casing and such other troubles. The pump performance should
be checked for noise and vibration.

11.3 Periodical checks

3.1 Temperature of bearing should be measured by a thermometer. Safe maximum temperature a
bearing can attain is 80°C
3.2 The lubricants of bearing should be checked. Lubricant might get contaminated with foreign
material or get blackened due to overheating. In such a case, bearing should be flushed and
cleaned and changed with fresh lubricant.
3.3 Check the stuffing box leakage, Normal leakage should be sufficient to dissipate heat
generated. In case the packing’s are worn out, all packing rings should be replaced. Replacement of
one or two rings or addition of rings should never be done.
3.4 alignment of pump unit should be checked. Due to operational vibration, atmospheric
temperature or stress induced by the weight of the piping, the alignment may get disturbed.
3.5 sufficient quantities of suitable lubricant and stuffing box packing should be available in stock
for daily and emergency.

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 3.6 Measuring instrument should be calibrated periodically.
3.7 A guide for preventive maintenance for normal application is given below. Unusual application,
dusts etc, and may require more frequent inspection and service.

S. No Item Action Required Frequency/ Hours of

operation
1 Packing Box Inspect for excess leakage. 150 Hours as
Adjust and replace packing necessary/every week
2 Mechanical Seal Replace or clean 2000 hrs or half yearly
3 Pump alignment/check fixing bolt Check for change in alignment Six monthly
4 Vibration and bearing Check for change in Vibration Every week
temperature & temp.
5 Bearing Lubricate Every 2000 hrs but at
least once a year.

11.4 ANNUAL CHECKS

4.1 The Pump should be overhauled completely to check the clearance and replace worn out parts.
Clearance between impeller and casing ring, shaft sleeve and gland/ throat bush, lantern ring and shaft
sleeve etc are very important, The bearing should be cleaned and checked thoroughly and lubricated.
The stuffing box packing should be replaced and lantern ring should be correctly located.
4.2 The effects of liquid handled on pump components should be checked. If abnormal corrosion,
erosion is observed the component should be replaced with that of suitable material.
4.3 The auxiliary pipe line and functioning of the auxiliary system should be checked. The main pipe
line should be checked for sealing leakage etc.
4.4 Full running tests may be carried out to check whether there is any fault in the performance in
comparison with original performance.
4.5 Piping support should be checked so that pipe does not induce unwanted stress on the pump.
12.5.1 Bearing: SMF pumps are fitted with one Bearing and one Thrust Bearing on the drive end side
and one Ball Bearing on nondriving end side.
12.5.2 Bearing details:

Driving end Non driving Bearing life Oil Fill in

Model
ball/thrust bearing end bearing in hours liters
SMF 17½ /20 30,000
6408/51310 6408 1
SMF 20/25
SMF 25/25 25,000
6410/51312 6410 1.7
SMF 25/30 20,000
SMF 30/30
SMF 30/30H 30,000
SMF 35/35 6412/51314 6412 25,000 2.5
SMF 35/40 20,000
SMF 40/40 6415/51320 6415 25,000 3.8
SMF 40/45 6415/51320 6415 20,000 3.8
SMF 50/50 25,000
6418/51322 6418 6.7
SMF 55/60 20,000
SMF 60/65 6324/51328 6324 20,000 9.7
The above bearing numbers refer to SKF standards.

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12.6.1 Bearing lubrication

The lubrication should be confirmed to following grades of Oil available in market or

equivalent. This Oil is acceptable for bearing temp of 5°c to 150°c
The bearings are lubricated by grease. Lubrication provides a film between the roller
elements and races which reduces the friction and prevents excessive temperature rise of the
bearings. The normal life of the bearing is terminated by fatigue only. Improper lubrication
practices are the main reason for failure of the bearings. One can follow the following practice.
a. Keep lubricant clean, free from dust, rain, moisture, etc., by storing in dust‐tight container.
b. Clean up the lubricant fittings before re‐lubricating.
c. Use clean dispensing equipment.
d. The bearing temperature may be allowed to rise 40ºC above room temperature, but should
not exceed 80ºC.
e. The period of First refilling is every 300 hours.
f. All bearings in SMF pumps are oil lubricated. The specifications of the oil are under:‐
Lubrication: Oil refined, de‐waxed and free from oxidation having.

Specification of oil

For lubrication of bearing use oil as per SAE 20w / 20or. CLP 68 to DIN 5157 or ISO – VG 46
having properties as given blow.
Kinematic viscosity at 40ºC Min – 41.4 mm²/sec and max 50.6 mm²/sec.
Flash point +175ºC, Solidification point -15ºC
Period of lubrication: After every 1000 running hours.
Quantity of Oil: As shown in the table 12.5.2
g. The Oil used could be of following make and Oil:

Manufacturer Speed up to 1800 RPM Speed 2900 RPM

and less
Indian Oil Servo system 81 Servo system 57
Hindustan petroleum ENKLO 57 ENKLO 53
ESSO TERESSO-68 TERESSO-46
SHELL TELLUS-68 TELLUS- S 46
CASTROL HYS PIN AWS 68 HYS PIN AWS 68
MOBIL OIL DTE 26 DTE 24
TEXACO PROMAX REGAL R&O 68 REGAL R&O 46

Page 31
12.6.2 SEALING & COOLING LIQUID DETAILS

The sealing liquid is forced into the gland and lantern ring area by a pressure higher than the
pump pressure so that the pump liquid does not came out of gland area. In horizontal split case
pumps where the impellers are designed for double entry (suction) the glands are placed on
suction side and therefore sealing liquid must have pressure higher than the pump suction
pressure. If the required temperature is more than 90ºC the gland region needs cooling. This
cooling enhances the lift of gland packing. Please ensure that the sealing liquid is:
a. Free from solids
b. Compatible with pumping fluid
c. Pressure higher than pump pressure (at least 1Kg/cm² higher)
d. Flow rate is around 2 to 3 Ltrs. /min.

12.6.3 FLUSHING OF PIPING SYSTEM

When the pump material is of CI or all iron construction, the pump must be thoroughly flushed prior
to initial starting to avoid contamination of the piping system.
12.6.4 Cooling of stuffing box bearing housing
[Link] Cool the gland pack stuffing box when pumping liquid above 80°.c
[Link] Cool mechanical seal stuffing box when pumping liquid temperature above 110°.c. The limit
is subject to change as per seal manufactures recommendation
12.6.5 Diametrical clearance

A. Check clearance between impeller and suction cover as per following chart. The clearance
should be within max. And min. limit. (In case of SMF pumps)

Clearance in mm.
Pump Type
Max. Min.
1. SMF 17.5/20 to 40/45 0.65 0.4
2. SMF 50/50 to 60/65 0.93 0.65

B. Check clearance should be within max and mini limit.

Sr.
Pump Type Diametrical Clearance between casing Ring & Impeller in mm
No.
CI/Br [Link].
Max. Mini. Max. Mini.
1 SMF 20/25 0.581 0.42 0.831 0.67
2 SMF 25/25
SMF 25/30 0.622 0.44 0.872 0.69
Suc./Del. Side Suc./Del. Side Suc./Del. Side Suc./Del. Side
3 SMF 35/35 0.783/0.83 0.586/0.612 1.039/1.08 0.836/0.862
4 SMF 40/40 0.824/0.83 0.606/0.612 1.074/1.08 0.856/0.862
5 SMF 55/60 0.86/0.94 0.51/0.54 1.11/1.19 0.76/0.79

Page 32
 12.6.6 Rotational Speeds:

Pump type Min. Speed Max. Speed

SMF 17½ /20 720 RPM 1750 RPM
SMF 20/25 720 RPM 1450 RPM
SMF 25/25 720 RPM 1450 RPM
SMF 25/30 720 RPM 1450 RPM
SMF 30/30 412 RPM 1450 RPM
SMF 30/30H 412 RPM 1450 RPM
SMF 35/35 412 RPM 970 RPM
SMF 35/40 412 RPM 970 RPM
SMF 40/40 412 RPM 970 RPM
SMF 40‐45 412 RPM 970 RPM
SMF 50/50 360 RPM 730 RPM
SMF 55/60 320 RPM 580 RPM
SMF 60/65 320 RPM 580 RPM

12. Stuffing box

Stuffing boxes are gland packed at the factory. All packing is subjected to wear and should be
regularly checked generally stuffing boxes in gland pumps should be checked for excessive leakage
every 150 hours of operation and gland should be readjusted if necessary.

Adjustment is accomplished by lightly tightening gland nuts, and then loosening them so they
can be adjusted with finger pressure to allow a small flow of liquid to lubricate the gland packing (30‐
60 drops per minute). If the flow of liquid has increased and cannot be reduced by lightly tightening
of the gland replace the packing and /or shaft sleeve.

Note
Do not tighten gland to stop all leakage, leakage is necessary to ensure cooling ,flushing and
lubrication of the gland packing and to prevent shaft sleeve damage
The stuffing box is fitted with lantern /water seal ring .The sealing chamber should be
connected to a source of clear, fresh water. The recommended water pressure is 1kg / cm 2 above
the maximum discharge pressure.
If water is not available, grease lubrication is acceptable .
 Stuffing box arrangement:
1. Standard arrangement: Packed stuffing box with lantern ring is the standard arrangement. It is
sealed internally. However, against special requirement, sealing by external fluid is also possible.
2. Cooling arrangement: Not provided but can be considered against specific request.
3. Mechanical Seal arrangement: Not provided but can be considered against specific request.
4. Standard gland packing specification: Graphite solid plate cotton Champion style 3116.
5. When the pumped liquid is other than water, gland packing to suit pumped liquid is provided.

Page 33
 Stuffing Box details:

No. of Position
Length packing from
Depth Size of of & impeller
in Bore packing packing Lantern L=Lantern
Model mm mm mm in mm Rings Ring
SMF 17½ /20 72 55 8 915 6 2+L+4
SMF 20/25 73 55 8 915 6 2+L+4
SMF 25/25 95 75 12 1040 5 2+L+3
SMF 25/30 95 75 12 1040 5 2+L+3
SMF 30/30 95 85 12 1188 5 2+L+3
SMF 30/30H 95 85 12 1188 5 2+L+3
SMF 35/35 95 85 12 1188 5 2+L+3
SMF 35/40 95 85 12 1188 5 2+L+3
SMF 40/40 135 115 16 1890 6 2+L+4
SMF 40‐45 135 115 16 1890 6 2+L+4
SMF 50/50 150 135 19 2265 6 2+L+4
SMF 55/60 160 135 19 2265 6 2+L+4
SMF 60/65 155 145 19 2450 6 2+L+4

 Sealing arrangements for stuffing boxes:

A. Lantern ring is located between the packing rings. Sealing liquid is fed internally to stuffing box
through a passage in the delivery casing.
B. Lantern ring is located between the packing rings. Sealing is provided by pumped liquid
through a piping to the stuffing box housing.
C. Lantern ring is located between the packing ring. Sealing liquid is fed in the stuffing box from
external source. Where pumps have to handle liquids containing abrasive particles, where
temperature is high or pump has to draw from a vessel under vacuum, sealing liquid should be
provided from external source.
D. Lantern ring located between the packing rings. Sealing is done by grease fed through a grease
cup/nipple where external clear water is not available or where water is not to mix with the
pumped liquid grease sealing may be adopted.
 Packing replacement
Use genuine packing suitable for handling liquid at required temperature, Pumping conditions,
and replacement procedure is as under.
1) Stop the pump.
2) Unbolt and remove gland
3) Use a flexible packing tool with hook/ wood screw attachment for removal of the packing and
water seal ring.
4) Clean packing box and shaft sleeve.
5) Inspect shaft sleeve for wear or rough finish and replace if necessary. Sleeve should have smooth
surface.
6) Install the packing box with new packing and lantern ring in the following order 2 ring packing + 1
lantern ring + 3/4 rings packing + gland. For renewing packing rings of suitable quality and
dimension. It should be cut clean in an oblique manner, the ends of the ring laid around the shaft
should slightly touch. If necessary, measure the ring length on the shaft out Side the pump.
Page 34
7) Before inserting the turns, clean the gland space. Apply light grease on gland packing and
individual rings are to be placed with joints staggered by 90⁰c and are to be pushed backwards
with the gland. Consider the sequence as mentioned above for lantern ring.
8) Slightly tighten by hand the gland nuts. During operation carefully tighten nut. The glands need
certain time to set. A correctly maintained gland should leak 30 to 60 drops per minute.
9) After prolonged stand still condition of the pump during which the gland may set hardened, they
have to be freed by turning shaft by hand.
10) Too excessively tightened gland would result in dry running, heating up, burning of the packing
material, and damage to the shaft/shaft sleeve. In such case the shaft with sleeve and gland will
have to be replaced.
11) The gland can only be tightened, if the shaft surface is perfect (Ground or polished), the bearing
are correct and sleeve are concentric. Maximum eccentricity of about 0.075 mm to 0.125 mm
depending on size and operating condition is permissible.
12) Packing base data given in table 3
THE GLAND SHOULD NEVER RUN DRY

13) Usual causes of packing failure

a. Packing has not been installed properly.
b. Packing used is not suitable for the temperature and pressure involved or may be subject to
attack by the liquid being handled.
c. Inner rings are not properly seated so that the outer rings are carrying the entire load.
d. Dust or foreign Material in the stuffing box is causing repaid wear of shaft or shaft sleeve.
e. Lantern ring not in line with the tapped hole sealing connection.

Page 35
Page 36
 TROUBLE CAUSE CURE
No liquid delivered Lack of Prime Packing too loose or defective, allowing air to leak into suction. Tighten
or replace packing and prime pump.
Not enough liquid Air leaking into Check that there is some leakage through stuffing box while operating-
delivered stuffing box if no leakage after reasonable gland adjustment new packing may be needed Or
Lantern ring may be clogged or displaced and may need centering in line
with sealing liquid connection Or
Sealing line may be clogged Or
Shaft or shaft sleeve below packing may be badly scored and allowing
air to be sucked into pump.

Defective packing Replace packing and check for surface smoothness of shaft or shaft sleeve.

Not enough pressure Defective packing As for preceding

Pump works for Air leaks into See proceeding.
awhile and quits stuffing box
Pump takes too Packing too tight Release gland pressure. Retighten reasonably. Keep leakage flowing-if
much power none; check packing, sleeve or shaft
Pump leaks Defective packing Replace worn packing. Replace packing damaged by lack of lubrication.
excessively Wrong type of Replace packing not properly installed or run-in. Replace improper packing with
at stuffing box packing correct grade for liquid being handled.
Scored shaft or Put in lathe and machine true and smooth or replace.
shaft sleeves
Stuffing box Packing too tight Release gland pressure.
overheating Packing not Release gland pressure and replace all packing if any burnt or damaged.
lubricated
Wrong grade of Check with pump or packing manufacturer for correct grade.
packing
Insufficient cooling Check if supply line valves opened or line clogged.
water to jackets
Stuffing box Repack
improperly packed
Packing wears too fast Shaft or shaft Re-machine or replace.
sleeve
worn or scored
Insufficient or no Repack and make sure packing loose enough to allow some leakage.
lubrication
Improperly packed Repack properly making sure all old packing removed and box clean.
Wrong grade Check with pump or packing manufacturer.
packing
Pulsating pressure Makes packing move and prevents it taking a 'set'. Remove cause of pulsation.
on external seal
Page 37
13. STUFFING BOX WITH MECHANICAL SEAL
In general mechanical seal are considered superior to conventional stuffing box packing. In some
particular cases, mechanical seals are the only satisfactory way of sealing a centrifugal pump stuffing box.
Mechanical seal are particularly recommended where.
1. Leakage must be held to a minimum.
2. Pressure and shaft speed are very high.
3. Corrosive and abrasive condition exits.
4. Volatile inflammable or toxic liquid are being pumped.
When specified, these pumps are equipped with mechanical seal
Various types of mechanical seal designs are available for sealing centrifugal pump stuffing boxes
and are determined by the application with mechanical seal. Tightening is carried by a fixed and rotating
ring in a plane perpendicular to the shaft. At least one ring is flexible to compensate for unavoidable
constructional in accuracies and the axial misalignment. The sliding surfaces are lapped between the
sliding surfaces; a liquid film is formed by the fluid pumped preventing metallic friction and providing for
cooling i.e. between the rings.
14.1 When the mechanical seal is functioning satisfactorily without any leakage etc, preventive
maintenance is not advised. If leakage occurs a thorough check up is needed. Like other parts in
equipment, the mechanical seals are subject to wear at the mating faces of the rotating and
stationary ring. The rate of wear will differ with the operation or condition and various other factors
such as lubricating properties of liquid being pumped, the presence of impurities in liquid and other
operating condition.
Before assembly, check up the following points to ensure proper fitting and satisfactory operation of
mechanical seal.
1. Shaft sleeve OD should be within +0.00mm or ‐0.05 mm for specified seal size.
2. Leading edge of shaft sleeve is chamfered.
3. Run out of the shaft at the seal face is within 0.05 mm.
14.2 If the following working conditions are maintained, a Life of several years with a leakage free
operation can be obtained.
1. The friction heat generated has to be dissipated. This is done by flushing with the liquid or by
cooling the seal.
2. Mechanical damage to the running surfaces should be avoided .Damage can be caused by the
ingress of solids, especially. Fine dust, by solidification of the fluid between rings, precipitation of
solid material by evaporation etc. Avoid dry running, which would destroy the running surfaces
very quickly. Dry run is due to operation without fluid , evaporation of the fluid between the sliding
ring For Smooth run of the shaft, concentric installation of the seal /gland parts is essential Flushed
fluids are different from the fluid being pumped. IF flushing is introduced from an external source,
it should be done at minimum pressure of 0.7 kg/cm2 above pressure of liquid at stuffing box. The
flushing liquid quantity should be approx 0.3 to 0.5 m3/hr. Flushing at the seal faces is necessary to
provide lubrication, heating or cooling of the seal faces and den sing action, Pump should not be
run without flushing at the seal face unless recommended by seal manufacturer

Page 38
14.3 Assembly and disassembly of mechanical seal following procedure apply
1. Certain elastomers are attacked by oil if such parts are used. The shaft must not be lubricated with
oil for mounting the ring. It is recommended to grease the shaft with talcum powder or soapy
water before installing them.
2. Edges and passages of shaft have to be very carefully rounded off to avoid damaging the lips of
elastomers and o‐ring
3. Protect sliding surfaces from dust (Especially oily dust) and filling from work benches and hands.
Touch with only clean hands, Never leave sliding surfaces exposed. Put them only on clean cloth or
paper; unpack mechanical seal only at the time of installation.
4. Take care of exact spring tension during installation , Very carefully check developed length
5. Do not grind worn sliding surfaces with each other, separately re machine/ grind surface and lap on
a lapping machine. Check plainness
6. The surfaces on which elastomers (o‐rings, wedge rings) are resting have to be polished. The
tolerance specified have to be carefully observed
14.4 Installation
Prior to installation
1. Check surfaces at the face of the seal housing and at the bottom of the seal housing to ensure that
they are clean, flat and free from dirt and burrs. The face surface must be smooth to form a good
sealing surface for o‐ring.
2. Check that shaft/shaft sleeve is smooth and free of burrs, nicks and sharp corners that could
damage the o‐ring or shaft packing. When further clean up is required protect the seal
remove burse, sharp Carnes by using a strip of emery paper /cloth file threads over the shaft
threads, file threads / around the key way with a smooth file , sharp edges must be removed.
3. Remove all chips and dust from the shaft area
4. Check that all rotary unit parts of the seal fit over shaft. A pre check be made by removing the o‐
ring to the seal and then installing seal on the shaft. Further shaft clean up will be necessary when
seal will not pass all the way in seal housing
5. Remove the seal after the pre check and reinstall the sleeve o ring.
6. Lubricate the shaft and sleeve ID with lubricant recommended by manufacturer. When no
lubricant is recommended by mechanical seal manufacture. Use following
1. Light oil (SAE‐10)
2. Silicone lubricant
3. Soapy water / liquid detergent
Oil based lubricant will damage EPR/ EPDM Elastomer o‐ring silicon and soapy water are safe for
EPR/ EPDM elastomes o‐rings.
7. Install the o‐ring between the seal housing and seal. Install seal cover over the shaft and slide into
position against the face of the seal box. Take care when passing the sleeve and o‐rings over the
key ways or threads to avoid damaging the o‐ring.
8. Position seal gland on discharge head seal housing and secure with cap screens. Tighten cap
screw gradually and uniformly.

Page 39
 Note
1. Do not pump carbon members against the shaft as they may chip crack or break.
2. Do not over tighten cap screws on gland. This can distort seal seat and cause seal failure
3. Install all seal piping as required prior to making connections of seal liquid pressurizing lines, Make
sure seal housing and all sealing liquid lines are flushed free of dust , scale and other particles that
would be abrasive to the sealing faces.
a. Impeller adjustment is required prior to installation
b. Secure collar set screw, set proper spring compression.
14.5 OPERATION
1. The seal should never run dry, even to check for rotation. A Water source must be provided to
cool and lubricate faces during pump operation, the lubricating media or external water source.
2. If an external water source is used, it must be clean to within 100 micron and introduced to the
seal prior to each motor start

Adequate flow must be provided to maintain (15 fps)/ (5 mps) minimum velocity between the
bushing and shaft.
Some seal may swat at initial stage. This condition should cease after a short period as the seal
faces lap together. Operate and monitor the seal until leakage subsides. In no case it should exceed 40
drops per minutes.
14.6 Routine maintenance
Periodically (100 hours of operation / one week) check seal for leakage.
Seal removal
Stop the drive and lock out the power so that driver cannot start accidently.
1. Disconnect piping to seal gland
2. Release spring tension to retain proper position. Loosen the collar set screw.
3. Loosen the cap screws securing the gland to the seal housing. Remove seal assembly.
4. Insect all parts of the seal, if any parts show sign of wear, the complete seal should be
replaced.
Install the new seal as per procedure given above.

14.7 Usual causes of mechanical seal failures and leakage between seal faces
1. Seal faces are worn or scored
2. Gland is bolted up unevenly
3. Stationary insert face is not perpendicular to the axis of shaft
4. The seal ring is binding
5. Wobbling of the rotating seal ring.
6. Cracked or broken stationary seal
7. Shaft run out through stuffing box.
8. Foreign particles between sealing faces
9. Loose set screws
10. Loss of spring compression
11. Mechanical seal is improperly installed.
Page 40
 14. OVERHAULING
With Normal daily operating spell. The pump will be due for overhaul after about 5000 working
hours. This work should be done by skilled personnel. Please refer to the cross sectional drawing while
dismantling and reassembling the pump.
15.1 DISMANTLING OF PUMP
1. Lock out power supply to motor.
2. Drain the delivery casing completely by removing drain plug.
3. Disconnect the pump from suction and delivery piping and auxiliary piping if any. Remove coupling
grub screws. Unscrew the bolts holding the pump on base plate and take out the pump.
4. Drain oil bearing housing by unscrewing the drain plug.
5. Remove, oil level indicator and accessories such as vent valve pump casing. Remove pump coupling.
Take out coupling key.
6. Remove the nuts holding down suction cover from delivery casing. Take out suction cover along with
(SMF pumps) casing ring by tightening jacking bolts. Take “o” rings from suction cover. (FIG 14)
7. Unscrew impeller nut. Take out the lock washer for impeller nut.
8. Remove the impeller SMF pump from pump shaft. (FIG 15)
9. Take out Impeller key.
10. Remove nuts holding down bearing housing to the delivery casing and take it out carefully. (FIG 16)
11. Unscrew the nuts holding gland plate and delivery casing. Take out gland plate by tightening jacking
bolts. Also remove “O’ ring. (FIG 17)
12. Unscrew gland nuts and remove gland. Take out gland packing and lantern ring.
13. Remove stuffing box bush from delivery casing by removing hexagonal bolts.
14. Remove shaft sleeve ‘O’ ring and key for impeller and shaft sleeve. Take out liquid deflector. (FIG 18)
15. Remove bearing cover DE along with oil seal removing bolts and by tightening release bolts. Also
remove bearing cover from non‐driving side along with oil seal by unscrewing bolts. (FIG 19)
16. Take out shaft from bearing housing along with bearing lock nut, bearing nut, ball bearing DE, thrust
bearing, cartridge and ball bearing NDE. (FIG 20)
17. Unscrew lock nut and bearing nut.
18. Remove whole assembly that is cartridge, ball bearing D.E., thrust bearing by using suitable puller on
cartridge. (FIG 21)
19. Remove boll bearing NDE and take out shoulder ring.
This completes the dismantling of the pump.

Before proceeding with reassembly of rotating unit and pump check the following:
a. Ball bearings are rotating freely and smoothly. Renew them if they are not rotating freely or if
the races are deteriorated.
b. Check the shaft for possible run out. Remove the same before reassembly. (FIG 22)
c. Remove any dust or rust from parts and if necessary apply new paint/coating on the same.
d. Clean all the parts thoroughly with kerosene or petrol.
e. If reassembly is not be made immediately, apply rust preventive, coating on all machined
surfaces.
f. Examine all the parts for refitting worn out etc. Damaged or corroded parts should be replaced
by new.
g. Ensure that newly fitted parts are free from damage and burrs.
h. Examine deflector, ‘O’ rings for damage or deterioration. If replaced with new make sure that
they are of requisite dimensions.
i. Check clearance between impeller and suction cover as per chart. (12.6.5 ‐ A). The Clearance
should be within max. and min. limit in SMF pumps.
j. Check clearance between casing ring and impeller as per chart (12.6.5 ‐ B). The clearance should
be within max and mini limit.

Page 41
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Page 50
15.2 REASSEMLY PROCEDURE

1. Wipe clean light oil cover shaft.

2. Insert shoulder ring from NDE side and fit ball bearing NDE.
NOTE:‐
a. Heat the bearing to 90ºC, 100ºC and push the bearing on to shaft remember to place the
spacer ring of the bearing on the shaft shoulder and face should be square to the axis. (Fig23)
b. It is absolutely necessary to place bearings correctly.
3. Fit the thrust bearing in small bearing housing. (Fig24)
4. Fit ball bearing at DE. Ensure that shoulder ring is filled at NDE prior to boll bearing. Fit bearing nut
and lock it by means of bearing lock nut. Fit gasket on thrust bearing cartridge. (Fig25)
5. Lift the shaft duly fitted with bearings and inserts it in bearing housing. (Fig26)
6. Fit bearing cover DE. & NDE. Ensure that gasket is duty fitted and shaft is rotating freely. (Fig27)
7. Fit stuffing box bush to delivery casing and stuffing box cover. Also fit stuffing box cover to delivery
casing. Ensure that ‘o’ ring is fitted properly. (Fig28 & 29)
8. Insert water deflector and gland.
9. Fit bearing housing to delivery casing and tighten the nuts to the value given below. (Fig30)

TORQUNE Nm
SEREUE SIZE
RATED MAXIMUM
M‐10 30 40
M‐12 50 60
M‐16 130 140
M‐20 250 260
M‐24 420 760

10. Fit shaft sleeve along with ‘O’ Ring and insert key for impeller and shaft sleeve. Ensure that ‘O’ ring is
fitted properly
11. Fit impeller key and impeller.
12. Insert lock washer for impeller nut over pumps shaft and tighten impeller nut, clock impeller nut with
lock washer. (Fig31)
13. Ensure that impeller rotates freely, Fit suction cover duly fitted with ‘O’ ring to delivery casing and
tighten the nuts. Ensure that pump shaft rotates freely. (Fig32)
14. Insert gland packing along with lantern ring and tighten the gland. Do not over tighten it.
15. Fit coupling key and fit pump coupling over shaft.
16. Install the pump on base plate and make suction and delivery as well as auxiliary pipe connections.
17. Fill the oil in bearing housing. Align motor coupling with pump coupling and fix coupling grub screws.

This completes the reassembly of the pump.

Page 51
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Page 61
15. TROUBLE SHOOTING

PROBLEM POSSIBLE CAUSE RECOMMENDED REMEDY

No discharge or Positive Head Required. Positive Head Required.
flow with pump
running.
Direction of rotation wrong. After confirming wrong rotation, reverse any tow of
three leads in three‐phase motor.
Entrained Air leak from Check suction flange connection as well as gasket.
atmosphere on suction side.
Clogged suction line or casing Clean the suction line & the pump.
which may be due to a fibrous
product of large solids.
Damaged pump shaft, impeller Replace damaged parts.
Pump used is of very high Check for proper impeller dia meter on curve and
Hydraulic unbalance capacity and is run by excessive rectify.
throttling of delivery and suction
valve.

Pump operates for Insufficient NPSHA Positive Head Required at least two meter.
short period, then Entrained Air leak from Check suction flange connection as well as gasket.
loses prime atmosphere on suction side.
Cavitation ‐ insufficient NPSH Refer to recommended remedy
available.
abnormal fluid rotation due to Redesign suction piping header, elbows and
Excessive noise complex suction piping number of planes to a minimum to avoid adverse
from wet end. fluid rotation as it approaches the impeller.
Impeller rubbing Check and reset impeller clearance.
Check outboard bearing assembly for axial end
play.
Excessive noise Bearing contamination appearing Work with clean tools in clear surroundings.
from power end on the race ways as scoring, Remove all outside dirt from housing before
running. pitting, scratching or rusting exposing bearing. Handle with clean dry hands.
caused by adverse environment Treat a used bearing as carefully as a new one. Use
and entrance of abrasive clean solvent and flushing oil.
contaminants from atmosphere. Protect disassembled bearing from dirt and
moisture. Keep bearings wrapped in paper or clean
cloth while not in use. Clean inside of housing
before replacing bearings. Check oil seals and
replace as required. Check all plugs and tapped
openings to make sure that they are tight.

Misalignment of pump with Check for proper alignment of pump.

motor.
Brinelling of bearing identified by When mounting the bearing on drive shaft use a
indentation on the ball races proper size ring only. Be sure when mounting a
usually caused by incorrectly bearing to apply the mounting pressure slowly and
applied forces in assembling the evenly.
bearings or by shock loading such
as hitting the bearing or drive
shaft with a hammer.

Page 62
False Brinelling of bearing identified Correct the source of vibration. Where bearings
again by either axial or are oil lubricated and employed in units that
circumferential indentations usually may be out of service for extended periods, the
caused by vibration of the balls drive shaft should be turned over periodically
between the races in a stationary to relubricate all bearing surfaces at intervals of
bearing. one‐to‐three months.
Thrust overload on bearing identified
by flaking ball path on one side of the
outer race or in the case of maximum
capacity bearing, may appear as a Follow correct mounting procedures for
spelling of the races in the Vicinity of bearings.
the loading slot. These thrust failures
are caused by improper mounting of
the bearing or excessive thrust loads.
Misalignment identified by fracture
of ball retainer or a wide ball path on
the inner race and a narrower cocked
ball path on the outer race.
Misalignment is caused by poor Handle parts carefully and follow
mounting practices or defective drive recommended mounting procedure. Check all
shaft. For example bearing not pares for proper fit and alignment.
square with the centerline or possibly
a bent shaft due to improper
handling.
Bearing damaged by electric arcing Where current shutting through the bearing
identified as elect etching of both cannot be corrected a shunt a shunt in the from
inner and outer ring as a pitting or of a slip ring‐assembly should be incorporated.
crate ring. Electrical arcing is cause by Check all wiring, insulation and rotor windings
a static Electrical charge emanating to be sure that they are sound and all
from belt drives, electrical leakage or connections are properly made. Where pumps
short circuiting. are belt drive, consider the elimination of static
charges by proper groundling or consider belt
material that is less generative only. Be sure
when mounting a bearing to apply the
mounting pressure slowly and evenly.
Bearing damage due to improper Be sure the lubricant is clean. Be sure proper
lubrication identified by one of more amount of lubricant is used. The constant level
of the following. oiler supplied with pumps will maintain the
Abnormal bearing temperature rise. proper oil level if it is installed and operating
A stiff cracked grease appearance. properly. In the case of grease lubricated
A brown or bluish discolor attain of bearings be sure that there is space adjacent to
the bearing races. the bearing into which it can rid itself of
excessive lubricant, otherwise the bearing may
overheat and fail prematurely. Be sure the
proper grade of lubricant is used.

Page 63
16. SPARE PARTS LIST
Recommended Stock of Spares for Two years operation.

S. No. Description No. Per set

1 Impeller 1

2 Gland piece 1

3 Lantern Ring 1

4 Deep groove ball bearing DE 1

5 Deep groove ball bearing NDE 1

6 Thrust Ball Bearing DE 1

7 Shaft Sleeve 1

8 Impeller Nut 1

9 Stuffing Box Bush 1

10 Stuffing Box packing 2 set.

11 Oil Seal for DE cover 1

12 Oil Seal for NDE cover 1

13 All 'O' Ring 2 set.

14 All Gasket 2 set.

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17. GENERAL INFORMATION & SAFETY REQUIREMENTS:
1.0 The products supplied by SINTECH have been designed with safety in mind. Where hazards cannot be
eliminated, the risk has been minimized by the use of guards and other design Features. Some
hazards cannot be guarded against and the instructions below must be complied with for safe
operation. These instructions cannot cover all circumstances; you are responsible for using safe
working practices at all times.
1.1 SINTECH products are designed for installation in designated area, which are to be kept clean and
free of obstructions that may restrict safe access to the controls and maintenance Access points.
A Pump duty Nameplate is fitted to each unit and must not be removed. Loss of this plate could
make identification impossible. This in turn could affect safety and cause difficulty in obtaining spare
parts. If accidental loss or damage occurs, contact SINTECH immediately.
1.2 Access to the equipment should be restricted to the personnel responsible for installation, operation
and maintenance and they must be trained, adequately qualified and supplied with appropriate tools
for their respective tasks.
1.3 SINTECH requires that all personnel that are responsible for installation, operation or maintenance of
the equipment, have access to and study the product instruction manual before any work is done
and that they will comply with all local and industry based safety instructions and regulations.
1.4 Ear defenders should be worm where the specified equipment noise level exceeds locally defined
safe levels. Safety glasses or goggles should be worn where working with pressurized systems and
hazardous substances. Other personnel protection equipment must be worn where local rules apply.
1.5 Do not wear loose clothing or jewellery which could catch on the controls or become trapped in the
equipment.
1.6 Read the instruction manual before installation, operation and maintenance of the equipment.
Check and confirm that the manual is relevant copy by comparing pump type on the nameplate and
with that on the manual.
1.7 Note the limits of product application‐permissible use specified in the manual. Operation of the
equipment beyond these limits will increase the risk from hazards noted below and may lead to
premature and hazardous pump failure.
1.8 Clear and easy access to all controls, gauges and dials etc. must be maintained at all times.
Hazardous or flammable materials must not be stored in pump rooms unless safe areas or racking
and suitable containers have been provided.
1.9 IMPROPER INSTALLATION, OPERATION OR MAINTENANCE OF THIS SINTECH PRODUCT COULD
RESULT IN INJURY OR DEATH.

SAFETY INSTRUCTIONS WHILE HANDLING AND STORAGE:

When lifting the pump, use the lifting points specified on general arrangement drawing. Use lifting
equipment having a safe working load rating suitable for the weight specified. Use suitable slings for
lifting pump which is not provided with lifting points. The use of fork‐lift truck and chain crane sling
equipment is recommended but locally approved equipment of suitable rating may be used
Do not place fingers or hands etc. into the suction or discharge pipe outlets and do not touch the
impeller, if rotated this may cause severe injury. To prevent ingress of any objects, retain the Protection
covers or packaging in place until removal is necessary for installation. If the packaging or suction and
discharge covers are removed for inspection purposes, replace afterwards to protect the pump and
maintain safety.

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SAFETY INSTRUCTIONS WHILE ASSEMBLY & INSTALLATION

Do not place fingers or hands etc. into the suction or discharge pipe outlets and do not touch the
impeller. If rotated this may cause severe injury. To prevent ingress of any objects, retain the Protection
covers or packaging in place unit removal is necessary for installation.

Do not touch any moving or rotating parts. Guards are provided to prevent access to these parts.
Where they have been removed for maintenance they must be replaced before operating the
Equipment.

Shaft alignment must be checked again after the final positioning of the pump unit and connection
to pipe work as this may have disturbed the pump or motor mounting position. If hot liquids (above
80⁰C) are being pumped. Alignment should be checked and reset with pump and motor at their normal
operating temperature. If this is not possible, SINTECH can supply estimated initial Offset figures to suit
extreme operating temperatures.

Failure to support suction and delivery pipe work may result in distortion of the pump casing with
the possibility of pump failure.

SAFETY INSTRUCTIONS WHILE COMMISSIONING & OPERATION

Do not touch any moving or rotating parts. Guards are provided to prevent access to these parts,
where they have been removed for maintenance they must be replaced before operating the
equipment.

Check that the pump is primed. Pump should never be run dry as the pumped liquid acts, as
lubricant for the close running fits surrounding impeller and damage will be incurred.
Failure to supply the stuffing box mechanical seal with cooling of flush water may result in damage
and premature failure of the pump.

Do not touch surfaces which during normal running will be sufficiently hot to cause injury. Note
that these surfaces will remain hot after the pump has stopped; allow sufficient time for cooling before
maintenance. Be cautious and note that other parts of the pump may become hot if a fault is
developing.

Do not operate water pumps in temperatures below freezing point, without first checking that the
pumped fluid is not frozen and the pump is free to turn. Pumps in these environments should be
Drained down during inactivity and re‐primed before starting.
In addition to local or site regulations for noise protection, SINTECH the use of personal ear
protection equipment in all enclosed pump rooms and particularly those containing diesel engines car
must be taken to ensure that any audible alarm or warning signal can be heard with ear defenders
worn.
Be aware of the hazards relating to the pumped fluid, especially the danger from inhalation of
noxious and toxic gases, skin and eye contact or penetration. Obtain and understand the hazardous
substance data sheets relating to the pumped fluid and note the recommended emergency and first aid
procedures.

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SAFETY INSTRUCTIONS WHILE MAINTENANCE & SERVICING

Before attempting any maintenance on a pump particularly if it has been handling any form of
hazardous liquid. It should be ensure that the unit is safe to work on. The pump must be flushed
thoroughly with suitable cleaner to purge away any of the product left in the pump components. This
should be carried out by the plant operator and a certificate of cleanliness obtained before Starting
work. To avoid any risk to health it is also advisable to wear protective clothing as recommended by the
site safety officer especially when removing old packing which may be contaminated.

Check and ensure that the pump operates at below the maximum working pressure specified in the
manual or on the pump nameplate and before maintenance, ensure that the pump is drained down.

Wear a suitable mask or respirator when working with packing and gasket components which
contain fibrous material, as these can be hazardous when the fibrous dust is inhaled. Be cautions, if
other supplier’s components have been substituted for genuine SINTECH parts, these may then contain
hazardous materials.

Be aware of the hazards relating to the pumped fluid, especially the danger from inhalation of
noxious and toxic gases, skin and eye contact or penetration. Obtain and understand the hazardous
Substance data sheets relating to the pumped fluid and note the recommended emergency and first aid
procedures.

Isolate the equipment before any maintenance work is done. Switch off the mains supply remove
fuses, apply lock‐outs where applicable and affix suitable isolation warning signs to prevent inadvertent
reconnection. In order to avoid the possibility of maintenance personnel inhaling dangerous fumes or
vapors, it is recommended that the maintenance work be carried out away from the pump locations by
removal of bearing housing and shaft assembly to a suitable to a suitable maintenance area.

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 ANNEX ­ 1
ORDER FORM FOR PUMP SPARE PARTS
ORDERING INSTRUCTION

1. Date of order / Enquiry.

2. Your reference.

3. Name plate information.

(Every pump has the following plate fastened to the Pump providing necessary identification of the Pump.)

A. W.O.

B. Model

C. S. No.

D. M³/HR

E. MWC

F. Motor kw.

G. RPM

H. SUC

I. DEL
Image of Name Plate

4. Part Name (Refer to cross section drawing.)

5. Part No.

6. Pump Application.

7. MOC of required Part.

8. Quantity.

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NOTE –
Diagrams given in this manual are only for reference and
are indicative. The actual product may differ from this
Technical data and product design / drawings are subject
to change without notice.

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